RU2799837C2 - Aerosol generation - Google Patents

Abstract

FIELD: aerosol generation.

SUBSTANCE: invention is proposed to create a product in which the inhaled aerosol or vapour is obtained by releasing compounds from the substrate material by heating, without burning. It is achieved by the fact that the substrate for the generation of an aerosol contains a material for the production of an aerosol, while the specified material for the production of an aerosol contains an amorphous solid material, and the specified amorphous solid material contains a substance for the generation of an aerosol, while heating the material for the production of an aerosol to 370° With a period of time equal to ten seconds, with an air flow of 1.95 l/min, at least 65% wt. substance to produce an aerosol is converted into an aerosol; moreover, said aerosol generating substrate contains a carrier material on which an amorphous solid material is provided, and the technical result is achieved by an aerosol generating product containing such a substrate and an assembly device containing such a substrate.

EFFECT: creation of a product in which the inhaled aerosol or vapour is obtained by releasing compounds from the substrate material by heating, without burning.

13 cl, 7 dwg

Description

The field of technology to which the invention belongs

The present invention relates to the production of an aerosol.

State of the art

In smoking articles such as cigarettes, cigars and the like, tobacco is burned during use to create tobacco smoke. In alternatives to these types of articles, an inhalable aerosol or vapor is produced by releasing compounds from the substrate material by means of heat, without incineration. Said articles may be referred to as non-combustible smoking articles or aerosol generating devices.

One example of such articles is a heating device in which compounds are released by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain tobacco material. Heating vaporizes at least one component of the material, typically forming a respirable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices, or tobacco heating products. Various designs are known that are capable of evaporating at least one component of the aerosolizable material.

As another example, there are electronic cigarette/tobacco heating product hybrid devices known as electronic hybrid tobacco devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce a vapor or aerosol that can be inhaled. The device further comprises a solid aerosolizable material (which may or may not contain tobacco material) and components of the material are entrained in the inhalable vapor or aerosol to generate a respirable environment.

Disclosure of invention

In the most general sense, the invention provides an aerosol generation substrate that comprises an aerosol generation material, said aerosol generation material comprising an amorphous solid material, said amorphous solid material comprising an aerosol generation substance, wherein when the aerosol generation material is heated to 370° C. for a period of ten seconds, with an air flow of 1.95 l/min, at least 65% by weight of the aerosol generating material is converted to an aerosol.

In some embodiments, the aerosol generating material comprises an amorphous solid material, said amorphous solid material comprising:

- gelling agent in the amount of 1 - 60 wt.%; and/or

- substance for the production of aerosol in the amount of 5 - 80 wt.%; and/or

- active substance in the amount of 10 - 60 wt.%;

- and, if necessary, flavoring;

these masses being calculated on a dry mass basis.

In specific embodiments, the amorphous solid material contains:

- gelling agent in the amount of 1 - 60 wt.%; and/or

- substance for the production of aerosol in the amount of 5 - 80 wt.%; and/or

- tobacco extract in the amount of 10 - 60 wt.%;

- and, if necessary, flavoring;

these masses being calculated on a dry mass basis.

In some embodiments, the aerosol generation substrate contains flavorant in an amount of from about 0.1 to 80% by weight, values calculated on a dry weight basis. In particular embodiments of the invention, the aerosol generation substrate contains a flavoring agent in an amount of from about 0.5 to 60 wt.%, and the values are calculated based on dry weight.

The invention also provides an aerosol generation article that includes such an aerosol generation substrate. The invention also provides an aerosol generation assembly that includes such an aerosol generation substrate or aerosol generation article and a heater that is configured to heat, but not burn, the aerosol generation substrate.

In accordance with other aspects of the invention described herein, the use of an aerosol generating substrate, an aerosol generating article, or an aerosol generating assembly for the purpose of generating an inhalable aerosol may be provided.

Additional features and advantages of the invention will become apparent from the following description, given by way of example only and with reference to the accompanying drawings.

Brief description of the drawings

fig. 1 is a view schematically showing a cross section of one example of an aerosol generating article;

fig. 2 is a perspective view showing the article of FIG. 1;

fig. 3 is a view schematically showing a cross section of one example of an aerosol generating article;

fig. 4 is a perspective view showing the article of FIG. 3;

fig. 5 is a perspective view schematically showing a cross section of one example of an aerosol generating device assembly.

fig. 6 is a view schematically showing a cross section of one example of an aerosol generating assembly;

fig. 7 is a perspective view schematically showing a cross section of one example of an aerosol generating device assembly.

Implementation of the invention

The aerosol generating material described herein comprises an "amorphous solid material", which may alternatively be referred to as a "monolithic solid material" (i.e., not fibrous) or "dried gel". An amorphous solid material is a solid material that can retain some fluid, such as a liquid, within it. In some cases, the material for generating an aerosol contains an amorphous solid material in an amount of from 50 wt.%, 60 wt.% or 70 wt.% to about 90 wt.%, 95 wt.% or 100 wt.%. In some cases, the aerosol generating material consists of an amorphous solid material.

As noted above, the invention provides an aerosol generation substrate that comprises an aerosol generation material, said aerosol generation material comprising an amorphous solid material, said amorphous solid material comprising an aerosol generation substance, wherein when the aerosol generation material is heated to 370° C. for a period of ten seconds, with an air flow of 1.95 l/min, at least 65% by weight of the aerosol generating material is converted to an aerosol.

In some cases, when the aerosol generating material is heated to 370°C for a period of ten seconds, with an air flow of 1.95 l/min, at least 68 wt.%, 70 wt.%, 72 wt.%, 75 wt.% or 78 wt.% of the material for aerosol generating is converted into an aerosol.

The inventors have found that transfer of an aerosol generating agent from an amorphous solid material is more efficient than transfer from other aerosolizable materials such as tobacco.

This means that aerosol generating materials that contain amorphous solid materials can deliver the desired aerosol volume after a shorter heating period. In other words, such materials can be highly heated for short periods, which reduces power consumption and increases efficiency while delivering the required amount of aerosol per puff. Due to the high rate of transition of the aerosol generating material from amorphous solid material to respirable aerosol, it is only possible to heat such materials during puffing. If necessary, different sections of such material can be heated to provide an aerosol for different puffs.

In some cases, the amorphous solid material contains an active substance. For example, in some cases, the amorphous solid material contains tobacco extract and/or nicotine. In some cases, the amorphous solid material may contain the active substance in an amount ranging from about 1 wt.%, 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.% to about 70 wt.%, 50 wt.%, 45 wt.% or 40 wt.% (values calculated based on dry weight). In some cases, the amorphous solid material may contain tobacco extract and/or nicotine in an amount ranging from about 1 wt.%, 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.% to about 70 wt.%, 60 wt.%, 50 wt.%, 45 wt.% or 40 wt.% (values calculated based on dry weight).

In some cases, the amorphous solid material contains an active substance such as tobacco extract. In some cases, the amorphous solid material may contain tobacco extract in an amount of 5-60 wt.% (values are calculated based on dry weight). In some cases, the amorphous solid material may contain tobacco extract in an amount ranging from about 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.% to about 55 wt.%, 50 wt.%, 45 wt.% or 40 wt.% (values calculated based on dry weight). For example, the amorphous solid material may contain tobacco extract in an amount of 5-60 wt.%, 10-55 wt.% or 25-55 wt.%.

The tobacco extract may contain nicotine in such a concentration that the amorphous solid material contains nicotine in an amount ranging from 1 wt.%, 1.5 wt.%, 2 wt.% or 2.5 wt.% to about 6 wt.%, 5 wt.%, 4.5 wt.% or 4 wt.% (values calculated based on dry weight). In some cases, the amorphous solid material may lack nicotine other than nicotine derived from tobacco extract.

In some embodiments, the amorphous solid material does not contain tobacco material, but contains nicotine. In some such cases, the amorphous solid material may contain nicotine in an amount ranging from about 1 wt.%, 2 wt.%, 3 wt.%, or 4 wt.% to about 20 wt.%, 15 wt.%, 10 wt.% or 5 wt.% (values calculated based on dry weight). For example, the amorphous solid material may contain nicotine in an amount of 1-20 wt.% or 2-5 wt.%.

In some cases, the total content of the active substance and/or aroma may be at least about 0.1 wt.%, 1 wt.%, 5 wt.%, 10 wt.%, 20 wt.%, 25 wt.% or 30 wt.%. In some cases, the total content of the active substance and/or aroma may be less than about 80 wt.%, 70 wt.%, 60 wt.%, 50 wt.% or 40 wt.% (all values are calculated based on dry weight).

In some cases, the total content of tobacco extract, nicotine and flavor may be at least about 0.1 wt.%, 1 wt.%, 5 wt.%, 10 wt.%, 20 wt.%, 25 wt.% or 30 wt.%. In some cases, the total content of tobacco material, nicotine and flavor may be less than about 80 wt.%, 70 wt.%, 60 wt.%, 50 wt.% or 40 wt.% (all values are calculated based on dry weight).

In some cases, the amorphous solid material contains an aerosol generating agent in an amount of 5-80% by weight. In some cases, the amorphous solid material contains:

- gelling agent in the amount of 1 - 60 wt.%; and/or

- substance for the production of aerosol in the amount of 5 - 80 wt.%; and/or

- active substance and/or flavor in the amount of 0.1 - 60 wt.%;

and these masses are calculated on the basis of dry weight (DWB).

In some cases, the amorphous solid material contains an aerosol generating agent in an amount of 5-80% by weight. In some cases, the amorphous solid material contains:

- gelling agent in the amount of 1 - 60 wt.%; and/or

- substance for the production of aerosol in the amount of 5 - 80 wt.%; and/or

- tobacco extract and/or nicotine and/or flavor in the amount of 10 to 60 wt.%;

and these masses are calculated on the basis of dry weight (DWB).

The inventors have found that amorphous solid materials having such a composition can be efficiently heated to generate a respirable aerosol.

Moreover, the inventors have found that the transfer of active ingredients from such an amorphous solid material is more efficient than transfer from other aerosolizable materials such as tobacco. In some cases, heating the material to produce an aerosol to 370°C for a period of time equal to ten seconds, with an air flow of 1.95 l / min, at least 70 wt.%, 72 wt.%, 75 wt.%, 78 wt.% or 80 wt.% of the active ingredient is converted into an aerosol. In some cases, when the aerosol material is heated to 370°C for a period of ten seconds, with an air flow of 1.95 l / min, at least 70 wt.%, 72 wt.%, 75 wt.%, 78 wt.% or 80 wt.% of all active ingredients are converted into an aerosol.

As used herein, "active ingredients", which may alternatively be referred to as "volatiles" or "volatiles", refers to components of an amorphous solid material that have a physiological or sensory effect on the human body. More specifically, the active ingredients may contain nicotine or its derivatives, flavors and flavors with high vapor pressure. In some cases, the amorphous solid material contains nicotine. In some cases, the amorphous solid material contains a flavorant. In some cases, the flavoring contains or consists of menthol.

In some instances, the amorphous solid material may be a hydrogel and contains less than about 20 wt%, 15 wt%, 12 wt%, or 10 wt% water, values calculated based on wet weight (WWB). In some cases, the amorphous solid material may contain water in an amount of at least about 1 wt.%, 2 wt.% or 5 wt.% (WWB). In some cases, the amorphous solid material contains water in an amount of from about 1 wt.% to about 15 wt.%, or from about 5 wt.% to about 15 wt.%, values calculated based on wet weight. Desirably, the water content of the amorphous solid material may be from about 5 wt.%, 7 wt.% or 9 wt.% to about 15 wt.%, 13 wt.% or 11 wt.% (WWB), most suitably, this content was about 10 wt.%.

In some cases, the amorphous solid material may contain gelling agent in an amount of 1 to 60 wt.%, and these weights are calculated on the basis of dry weight. Suitably, the amorphous solid material may contain a gelling agent in an amount of from about 1 wt.%, 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.% to about 60 wt.%, 50 wt.%, 45 wt.%, 40 wt.%, 35 wt.%, 30 wt.% or 27 wt.% (all values calculated enes based on dry weight). For example, an amorphous solid material may contain a gelling agent in an amount of 1-50 wt.%, 5-40 wt.%, 10-30 wt.% or 15-27 wt.%.

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent contains one or more compounds selected from the group consisting of alginates, pectins, starches (and their derivatives), celluloses (and their derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent contains one or more of the following: alginates, pectins, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin, and polyvinyl alcohol . In some cases, the gelling agent contains alginate and/or pectin and may be combined with a hardening agent (such as a source of calcium) during the formation of an amorphous solid material. In some cases, the amorphous solid material may contain calcium-crosslinked alginate and/or calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30% by weight of the amorphous solid (values calculated based on dry weight). In some embodiments, the alginate is the only gelling agent present in the amorphous solid material. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

In some embodiments, the amorphous solid material may contain a gelling agent containing carrageenan.

The amorphous solid material may contain an aerosol generating agent in an amount of from about 5 wt.%, 10 wt.%, 20 wt.%, 25 wt.%, 27 wt.% or 30 wt.% to about 60 wt.%, 55 wt.%, 50 wt.%, 45 wt.%, 40 wt.% or 35 wt.% (DWB). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid material may contain an aerosol generating agent in an amount of 10-60 wt.%, 20-50 wt.%, 25-40 wt.% or 30-35 wt.%. In some instances, the aerosol generating agent contains one or more compounds that are selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some instances, the aerosol generating agent contains, consists essentially of, or consists of glycerol. The inventors have found that if the plasticizer content is too high, the amorphous solid material can absorb water (because the aerosol generating agent is hygroscopic), resulting in a material that does not provide a proper consumption experience when used. The inventors have found that if the content of the plasticizer is too low, the amorphous solid material can be brittle and break easily. The plasticizer content reported here provides flexibility to the amorphous solid material, which allows the amorphous solid material sheet to be wound onto a bobbin, which is useful in the manufacture of aerosol generating articles.

The amorphous solid material may contain tobacco extract in an amount of from about 10 wt.%, 20 wt.%, 30 wt.%, 40 wt.% or 45 wt.% to about 50 wt.%, 55 wt.% or 60 wt.% (DWB). For example, the amorphous solid material may contain tobacco extract in an amount of 20-60 wt.%, 40-55 wt.% or 45-50 wt.%. The tobacco extract may contain nicotine in such a concentration that the amorphous solid material contains nicotine in an amount of from about 1 wt.%, 1.5 wt.%, or 2 wt.% to about 6 wt.%, 5 wt.%, 4 wt.% or 3 wt.% (DWB). In some cases, the amorphous solid material may lack nicotine other than nicotine derived from tobacco extract.

In some cases, the tobacco extract may be an aqueous extract obtained by extraction with water. The tobacco extract may be an extract from any suitable tobacco such as single grade tobacco or tobacco blends, cut or whole leaf tobacco, including Virginia and/or Burley and/or Oriental tobacco. It may also be an extract from "fine" tobacco particles or tobacco dust, or exploded tobacco, stems, exploded stems, and other processed stem materials such as cut and rolled stems. The extract can be obtained from ground tobacco or reconstituted tobacco material.

In some cases, the amorphous solid material may contain a flavor. Suitably, the amorphous solid material may contain up to about 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, 20 wt.%, 10 wt.% or 5 wt.% aroma. In some cases, the amorphous solid material may contain aroma in an amount of at least about 0.1 wt.%, 0.5 wt.%, 1 wt.%, 2 wt.%, 5 wt.%, 10 wt.%, 20 wt.% or 30 wt.% (all values are calculated based on dry weight). For example, an amorphous solid material may contain aroma in an amount of 0.1-60 wt.%, 1-60 wt.%, 5-60 wt.%, 10-60 wt.%, 20-50 wt.% or 30-40 wt.%. In some cases, the flavor (if present) contains, consists essentially of, or consists of menthol. In some cases, the amorphous solid material is odorless.

In some embodiments of the invention, the amorphous solid material contains a filler in an amount of less than 60 wt.%, for example, in an amount of from 1 wt.% to 60 wt.% or from 5 wt.% to 50 wt.%, or from 5 wt.% to 30 wt.%, or 10 wt.% to 20 wt.%.

In other embodiments of the invention, the amorphous solid material contains a filler in an amount of less than 20 wt.%, suitably less than 10 wt.% or less than 5 wt.%. In some cases, the amorphous solid material contains a filler in the amount of 1 wt.%, and in some cases, the amorphous solid material does not contain a filler.

The filler, if present, may contain one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic sorbents such as molecular sieves. The filler may contain one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In specific cases, the amorphous solid material does not contain calcium carbonate, such as chalk.

In specific embodiments of the invention in which a filler is present, this filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. Without being limited by theory, it is believed that the presence of a fibrous filler in an amorphous solid material can increase the tensile strength of the material. This may be particularly useful in instances where the amorphous solid material is provided in the form of a sheet, such as where a sheet of amorphous solid material surrounds a rod of aerosolizable material.

In some embodiments of the invention, the amorphous solid material does not contain tobacco fibers. In specific embodiments of the invention, the amorphous solid material does not contain fibrous material.

In some embodiments, the aerosol generating material does not contain tobacco fibers. In specific embodiments, the aerosol generating material does not contain fibrous material.

In some embodiments, the aerosol generation substrate does not contain tobacco fibers. In particular embodiments of the invention, the aerosol generation substrate does not contain fibrous material.

In some embodiments, the aerosol product does not contain tobacco fibers. In particular embodiments of the invention, the aerosol generating article does not contain fibrous material.

In some cases, the amorphous solid material may consist or essentially consist of a gelling agent, an aerosol generating agent, an active agent, water, and optionally a fragrance. In some cases, the amorphous solid material may essentially consist or consist of glycerol, alginates and/or pectins, the active substance and water.

In some cases, the amorphous solid material may consist, or essentially consist of a gelling agent, aerosol generating agent, tobacco extract, water, and optionally flavor. In some cases, the amorphous solid material may essentially consist or consist of glycerol, alginates and/or pectins, tobacco extract and water.

In some cases, the aerosol generation substrate may further comprise a carrier material on which the amorphous solid material is provided. This carrier material can simplify, for example, manufacture and/or handling by: (a) providing a surface on which the slurry can be applied (and from which the slurry does not need to be further separated), (b) providing a non-tacky surface for the aerosol generating material, (c) providing some rigidity to the substrate.

In some cases, the aerosol generation substrate comprises a carrier material on which an amorphous solid material is provided. In some cases, the carrier material may be made from materials selected from metal foil, paper, carbon paper, parchment paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. In some cases, the carrier material may comprise or consist of tobacco material such as reconstituted tobacco leaf. In some cases, the carrier material may be made from materials selected from metal foil, paper, cardboard, wood, or combinations thereof. In some cases, the carrier material itself may be a multilayer structure containing layers of materials selected from the previous lists. In some cases, the carrier material may be impregnated with flavoring or additional tobacco extract.

In some cases, the carrier material may be substantially gas and/or aerosol impermeable, or may be completely gas and/or aerosol impermeable. This prevents the aerosol or gas from passing through the carrier material during use, thereby controlling the flow and ensuring that it is delivered to the user. This can also be used to prevent, in use, condensation or other deposition of gas/aerosol on, for example, the surface of a heater provided in the aerosol generating device assembly. Thus, consumption efficiency and hygiene can be improved in some cases.

In some cases, the carrier material in the aerosol generating article may comprise or may consist of a porous layer that is adjacent to the amorphous solid material. For example, the porous layer may be a paper layer. In some specific cases, the amorphous solid material is in direct contact with the porous layer; the porous layer adjoins the amorphous solid material and forms a strong bond. An amorphous solid material is obtained by drying the gel and, without being limited by theory, it is believed that the suspension from which the gel is obtained partially impregnates the porous layer (for example, paper), so that when the gel cures and forms cross-links, the porous layer is partially bonded to the gel. This provides a strong bond between the gel and the porous layer (and the dried gel and the porous layer).

Additionally, surface roughness can contribute to the bonding strength of the amorphous material and the carrier material. The inventors found that it is expedient that the roughness of the paper (for the surface adjacent to the carrier material) be in the range of 50 - 1000 Beck seconds, it is expedient that it be 50 - 150 Beck seconds, 100 Beck seconds (when measured, the air pressure is in the range of 50.66 - 48.00 kPa). (A Beck smoothness measuring device is an instrument that is used to determine the smoothness of a paper surface, in which air at a specific pressure flows between a smooth glass surface and a paper sample, and the time (in seconds) needed to leak a fixed volume between these surfaces is "Beck smoothness".)

Conversely, the surface of the carrier material, directed away from the amorphous solid material, may be located in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier material is positioned so that the rougher side is adjacent to the amorphous material and the smoother side is directed away from the amorphous material.

In one particular case, the carrier material may be a paper-based foil; the paper layer is adjacent to the layer of amorphous solid material and the properties described in the previous paragraphs are due to this adjunction. The back foil is substantially impermeable, providing control over the flow path of the aerosol. The back layer of metal foil can also serve to transfer heat to the amorphous solid material.

In another case, the foil layer of the paper-based foil is adjacent to the amorphous solid material. The foil is essentially impermeable, thus preventing the absorption of water in the amorphous solid material by the paper, which could weaken the integrity of the structure.

In some cases, the carrier material is made of or contains a metal foil such as aluminum foil. The metallic carrier material may enable better transfer of thermal energy to the amorphous solid material. Additionally or alternatively, the metal foil may function as a sensing element in an induction heating system. In particular embodiments of the invention, the carrier material comprises a metal foil layer and a support layer such as cardboard. In these embodiments of the invention, the thickness of the metal foil layer may be less than 20 µm, for example, from about 1 µm to about 10 µm, suitably about 5 µm.

In some cases, the carrier material may be magnetic. This functionality can be used to attach, in use, the carrier material to the device assembly, or can be used to shape particular shapes of the amorphous solid material. In some instances, the aerosol generation substrate may include one or more magnets, which can be used to attach the substrate to the induction heater when in use.

In some instances, the aerosol generating material may include heating means embedded in the amorphous solid material, such as resistive or induction heating elements.

In some cases, the thickness of the amorphous solid material may be from about 0.015 mm to about 1.0 mm. Suitably, this thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material with a thickness of 0.2 mm is particularly suitable. The amorphous solid material may contain more than one layer, and the thickness described herein refers to the total thickness of these layers.

The inventors have found that if the amorphous solid material is too thick, the heating efficiency is reduced. This negatively affects the power consumption during use. Conversely, if the amorphous solid material is too thin, it is difficult to manufacture and handle, a very thin material is more difficult to cast, and may be brittle, which jeopardizes aerosolization in use.

The inventors have found that the thicknesses of the amorphous solid material specified herein optimize the properties of the material in terms of these competing considerations. The thickness specified in this document is the average thickness of the material. In some cases, the thickness of the amorphous solid material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

The aerosol generating material containing the amorphous solid material may have any suitable basis weight, such as from 30 g/m ² to 120 g/m ² . In some embodiments, the aerosol generating material may have a basis weight of from about 30 to 70 g/m ² , or from about 40 to 60 g/m ² . In some embodiments, the amorphous solid material may have a basis weight of from about 80 to 120 g/m ² , or from about 70 to 110 g/m ² , or in particular from about 90 to 110 g/m ² . Such surface densities may be particularly useful when the aerosol generating material is contained in an aerosol generating article/device assembly in the form of a sheet or a shredded sheet (described further below).

The amorphous solid material may be in the form of a sheet. It can be included in the product in the form of a sheet. In some instances, the aerosol generating material may be provided as a flat sheet, as a grouped or assembled sheet, as a corrugated sheet, or as a rolled sheet (ie, in the form of a tube). In some such cases, the amorphous solid material of these embodiments may be contained in an aerosol generating article/device assembly in the form of a sheet, such as a sheet surrounding a rod of aerosolizable material (eg, tobacco). In some other cases, the material for generating an aerosol can be made in the form of a sheet and then can be crushed and included in the product. In some cases, the shredded leaf may be mixed with cut tobacco and incorporated into the product. In such cases, the aerosol generating material may have a mass per unit area of 80-120 g/m ² (so that it has a density that is comparable to cut tobacco and thus the components of the mixture do not separate from each other).

In some examples, the sheet-shaped amorphous solid material may have a tensile strength of from about 200 N/m to about 900 N/m. In some examples, such as when the amorphous solid material does not contain a filler, the amorphous solid material may have a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments of the invention in which the aerosol generating material is made into a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the amorphous solid material contains a filler, the amorphous solid material may have a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m. Such tensile strengths may be particularly useful for embodiments of the invention in which the aerosol generating material is contained in the aerosol generating article/device assembly in the form of a rolled sheet, suitably in the form of a tube.

In some instances, at least a portion of the aerosol generating material may be in the form of a rolled sheet that forms a tubular rod of the aerosol generating material. In such cases, the tubular nature of the aerosol generating material can be adapted for use in a variety of ways. In some cases, the aerosol generating article is configured for use with an aerosol generating assembly in which, in use, the heater is located within the tube. In other instances, the aerosol generating article is configured for use with an aerosol generating assembly in which, in use, the heater is located on the outside of the tube. In such cases, it may be that, in use, no components of the aerosol generating assembly assembly are located in the tube; instead, the tube provides a path for the flow of aerosol or vapor in use; this can reduce or prevent condensation of the aerosol or vapor on the reusable components of the aerosol generating assembly assembly, thereby improving consumption efficiency and hygiene. In some such cases, the outer wall of the tube may be substantially gas/aerosol impermeable or completely impermeable, further controlling the flow path.

In accordance with other aspects of the invention, there is provided an aerosol generating article that comprises the aerosol generating material described herein, and an aerosol generating assembly that includes such an aerosol generating substrate or article.

In some cases, the product or assembly may further comprise a filter and/or a cooling element. The cooling element, if present, may act or function to cool the gaseous or aerosol components. In some cases, it may act to cool the gaseous components so that they condense to form an aerosol. It may also act to separate very hot parts of the device assembly from the user. The filter, if present, may comprise any suitable filter known in the art, such as a cellulose acetate insert.

The heater in the device assembly is configured to heat, but not burn, the aerosol generating material. The heater may, in some cases, be a thin film electrical resistance heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat in use. The aerosol generating device assembly may comprise a plurality of heaters. The heater(s) may be battery powered.

In some instances, in use, the heater may heat, without combustion, the aerosolizable material(s) to temperatures ranging from 120ºC to 350ºC. In some instances, in use, the heater may heat, without combustion, the aerosolizable material(s) to temperatures ranging from 140ºC to 250ºC. In some cases, in use, substantially all of the amorphous solid material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the solid material is spaced from the heater at a distance of from about 0.010 mm to 2.0 mm, suitably from about 0.02 mm, 0.05 mm or 0.1 mm to 1.0 mm or 0.5 mm. In some cases, these minimum distances may reflect the thickness of the carrier material that supports the amorphous solid material. In some cases, the surface of the amorphous solid material may be directly adjacent to the heater.

In some cases, the heater may be embedded in the substrate to generate the aerosol. In some such cases, the heater may be an electrical resistance heater (with contacts available for connection to an electrical circuit). In other such cases, the heater may be a sensing element that is embedded in the aerosol generating substrate and that is heated by induction.

In some cases, the aerosol generating device assembly may be a "heat but not burn" device. That is, it may contain solid tobacco-containing material (and not contain liquid aerosolizable material). In some cases, the amorphous solid material may contain tobacco material. The "heat but not burn" device is described in WO 2015/062983 A2, which is incorporated herein in its entirety by reference.

In some instances, the aerosol generating device assembly may be an electronic hybrid tobacco device. That is, it may contain a solid aerosolizable material and a liquid aerosolizable material. In some cases, the amorphous solid material may contain nicotine. In some cases, the amorphous solid material may contain tobacco material. In some cases, the amorphous solid material may contain tobacco material and a separate source of nicotine. The individual aerosolizable materials may be heated by separate heaters, the same heater, or in one case, the downstream aerosolizable material may be heated by a hot aerosol that is derived from the upstream aerosolizable material. An electronic hybrid tobacco device is described in WO 2016/135331 A1, which is incorporated herein in its entirety by reference.

The aerosol generating article or device assembly may further comprise ventilation holes. In some cases, vents may be provided in the filter and/or cooling element. These openings may allow cooling air to be drawn into the article during use, which air may mix with the heated vaporized components, thereby cooling the aerosol.

Ventilation improves the production of visible heated vaporized components from the product as it heats up in use. The heated vaporized components are made visible by the process of cooling the heated vaporized components, so that a process of supersaturation of the heated vaporized components takes place. The heated vaporized components then undergo a droplet formation process, also known as active site formation, and eventually the particle size of the heated vaporized components aerosol increases due to additional condensation of the heated vaporized components and due to coalescence of newly formed droplets from the heated vaporized components.

In some cases, the ratio of cooling air to the sum of the heated vaporized components and cooling air, which is referred to as the ventilation ratio, is at least 15%. A ventilation ratio of 15% allows the heated vaporized components to become visible by the process described above. The visibility of the heated vaporized components allows the user to determine that the vaporized components have been exhausted and adds a sensory experience to the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated evaporative components. In some cases, the ventilation ratio may be at least 60% or 65%.

The assembly may include an integral aerosol generating article and a heater, or may include a heating device into which the article is inserted in use.

In FIG. 1 and 2 show a partial section and perspective view of an example of an aerosol generating article 101. The product 101 is configured to be used with a device containing an electrical power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 51 shown in FIG. 5-7 and described below. In use, the article 101 can be retractably inserted into the device shown in FIG. 5, at the insertion point 20 of the device 51.

The article 101 of one example is in the form of a substantially cylindrical rod which contains a volume of aerosol generating material 103 and a filter assembly 105 having the form of a rod. The aerosol generating material comprises the amorphous solid material described herein. In some embodiments of the invention, it may have the form of a sheet. In some embodiments of the invention, it may be in the form of a crushed sheet. In some embodiments, the aerosol generating material described herein may be incorporated in the form of a sheet or a shredded sheet.

The filter assembly 105 comprises three segments: a cooling segment 107, a filtration segment 109, and a mouthpiece segment 111. The article 101 includes a first end 113, also known as a mouthpiece or proximal end, and a second end 115, also known as a distal end. The volume of aerosol generation material 103 is positioned towards the distal end 115 of article 101. In one example, the cooling segment 107 is located adjacent to the volume of aerosol production material 103 between the volume of aerosol production material 103 and the filtration segment 109 such that the cooling segment 107 is adjacent to the aerosol production material 103 and the filtration segment 103. In other examples, there may be a separation between the volume of aerosol production material 103 and the cooling segment 107, and there may be a separation between the volume of aerosol production material 103 and the filtration segment 109. The filtration segment 109 is located between the cooling segment 107 and the mouthpiece segment 111. The mouthpiece segment 111 is located towards the proximal end 113 of the article 101, adjacent to the filtration segment 109. In one example, the filtration segment 109 abuts the mouthpiece segment 111. In one embodiment, the total length of the filter 105 assembly is between 37 mm and 45 mm, more preferably the total length of the filter 105 assembly is 41 mm.

In one example, the rod of aerosol generating material 103 is 34 mm to 50 mm in length, suitably 38 mm to 46 mm in length, suitably 42 mm in length.

In one example, the overall length of article 101 is 71 mm to 95 mm, suitably 79 mm to 87 mm, suitably 83 mm.

The axial end of the volume of aerosol material 103 is visible at the distal end 115 of article 101. However, in other embodiments, the distal end 115 of article 101 may include an end member (not shown) covering the axial end of the volume of aerosol material 103.

The body of aerosol generating material 103 is connected to the filter assembly 105 by an annular rim paper (not shown) which is positioned substantially around the circumference of the filter assembly 105, surrounding the filter assembly 105, and extending partially along the length of the body of aerosol generating material 103. In one example, the tipping paper is made from a 58GSM standard tipping paper. In one example, the length of the tipping paper is between 42 mm and 50 mm, suitably 46 mm.

In one example, the cooling segment 107 is an annular tube and defines an air gap within and around the cooling segment. The air gap provides a chamber for the flow of heated vaporized components produced from the volume of material 103 to generate aerosol. Cooling segment 107 is hollow and provides a chamber for accumulating aerosol, and yet is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and during use of product 101 during insertion into device 51. In one example, the wall thickness of cooling segment 107 is about 0.29 mm.

The cooling segment 107 provides a physical distance between the aerosol generating material 103 and the filtration segment 109 . The physical distance provided by the refrigeration segment 107 will provide a temperature differential along the length of the refrigeration segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference that is at least 40 degrees Celsius between the heated vaporized component entering the first end of the cooling segment 107 and the heated vaporized component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference that is at least 60 degrees Celsius between the heated vaporized component entering the first end of the cooling segment 107 and the heated vaporized component exiting the second end of the cooling segment 107. This temperature difference along the length of the cooling element 107 protects the temperature sensitive filtration segment 109 from the high temperatures of the aerosol generating material 103 when it is heated by the device 51. If there is no physical distance between the filtration segment 109 and the volume of the aerosol generating material 103 and the heating elements of the device 51, then the temperature sensitive filtration segment 109 may be damaged in use, thus not performing its functions as efficiently as desired.

In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is 20 mm to 30 mm, more preferably 23 mm to 27 mm, more preferably 25 mm to 27 mm, suitably 25 mm.

Cooling segment 107 is made of paper, which means that it consists of a material that does not produce problematic compounds, e.g., toxic compounds, when used near the heater of device 51. In one example, cooling segment 107 is made from a spirally wound paper tube, which provides a hollow inner chamber that still maintains mechanical rigidity. Spiral rolled paper tubes are capable of meeting the stringent dimensional accuracy requirements of high-speed manufacturing processes in terms of tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is an indentation made from rigid ficell or rim paper. Rigid ficell or tipping paper is made so that it has sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacture and during use of the product 101 during its insertion into the device 51.

The filtration segment 109 may be made of any filter material that is sufficient to remove one or more vaporized compounds from the heated vaporized components of the aerosol generating material. In one example, the filtration segment 109 is made of a monoacetate material such as cellulose acetate. The filtration segment 109 provides cooling and reduction of user irritation from heated evaporative components without reducing the amount of heated evaporative components to an unsatisfactory level for the user.

In some embodiments, a capsule (not shown) may be provided in the filtration segment 109. It can be located substantially centrally in the filtration segment 109, both along the diameter of the filtration segment 109 and along the length of the filtration segment 109. In other cases, it may be biased in one or more dimensions. In some instances, the capsule, if present, may contain a volatile component such as a flavoring agent or an aerosol generating agent.

The density of the cellulose acetate tow material for the filtration segment 109 controls the pressure drop in the filtration segment 109, which in turn controls the draw resistance for the article 101. Therefore, the choice of material for the filtration segment 109 is important in controlling the draw resistance for the article 101. In addition, the filtration segment performs the filtration function in the article 101.

In one example, the filtration segment 109 is made of 8Y15 filter tow material, which provides a filtering action for the heated vaporized material while reducing the size of the condensed aerosol particles that are produced from the heated vaporized material.

The presence of the filtration segment 109 provides an insulating effect by providing additional cooling to the heated vaporized components that exit the cooling segment 107 . Additionally, the cooling effect reduces the user's lip contact temperature on the surface of the filtration segment 109 .

In one example, the filter segment 109 is 6 mm to 10 mm long, expediently 8 mm.

The mouthpiece segment 111 is an annular tube and defines an air gap within and around the mouthpiece segment 111. The air gap provides a chamber for the flow of heated, vaporized components that flow from the filtration segment 109. Mouthpiece segment 111 is hollow and provides a chamber for accumulating aerosol and yet is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and during use of the product during insertion into device 51. In one example, the wall thickness of mouthpiece segment 111 is about 0.29 mm. In one example, the length of the mouthpiece segment 111 is between 6 mm and 10 mm, suitably 8 mm.

The mouthpiece segment 111 may be made from a spirally rolled paper tube that provides a hollow inner chamber while still maintaining critical mechanical rigidity. Spiral rolled paper tubes are capable of meeting the stringent dimensional accuracy requirements of high-speed manufacturing processes in terms of tube length, outer diameter, roundness and straightness.

The mouthpiece segment 111 has the function of preventing direct contact with the user of any liquid condensate that accumulates when exiting the filtration segment 109 .

It is clear that, in one example, the mouthpiece segment 111 and the cooling segment 107 can be made from the same tube, and the filtration segment 109 is located in this tube, separating the mouthpiece segment 111 and the cooling segment 107.

In FIG. 3 and 4 show a partial section and perspective view of an example article 301. The reference numbers shown in FIG. 3 and 4 are equivalent to the reference numerals shown in FIG. 1 and 2, but increased by 200.

In this example of product 301, which is shown in FIG. 3 and 4, a vent area 317 is provided in article 301 to allow air to flow into the inside of article 301 from outside of article 301. In one example, vent area 317 takes the form of one or more ventilation holes 317 provided in the outer layer of article 301. Ventilation holes may be located in cooling segment 307 to help cool article 301. ov holes and, preferably, each row of holes is located in a circle around the product 301 in a cross section that is essentially perpendicular to the longitudinal axis of the product 301.

In one example, there are from one to four rows of ventilation holes to provide ventilation to the article 301. Each row of ventilation holes may contain from 12 to 36 ventilation holes 317. The diameter of the ventilation holes 317 may be, for example, 100 to 500 µm. In one example, the axial spacing between the rows of ventilation holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the ventilation holes 317 are of the same size. In another example, the ventilation holes 317 are of different sizes. The ventilation holes can be made using any suitable technology, for example, one or more of the following technologies: laser technology, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before the article 301 is formed. The ventilation holes 317 are located so as to provide effective cooling of the article 301.

In one example, the rows of vent holes 317 are located at a distance that is at least 11 mm from the proximal end 313 of the article, suitably at a distance that is from 17 mm to 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is such that the user does not block the vent holes 317 when using the article 301.

Providing rows of ventilation holes at a distance of 17 mm to 20 mm from the proximal end 313 of the article 301 allows the ventilation holes 317 to be located on the outside of the device 51 when the article 301 is fully inserted into the device 51, as shown in FIG. 6 and 7. Due to the location of the ventilation holes on the outside of the device, unheated air can enter the product 301 through the ventilation holes from the outside of the device 51 to help cool the product 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 51 when the product 301 is fully inserted into the device 51. The length of the cooling segment 307 provides the first function of providing a physical gap between the heating device from the device 51 and the heat sensitive filter device 309, and the second function of allowing the ventilation holes 317 to be located in the cooling segment, while being located outside the device 51 when the product 301 is fully inserted into the device 51. As is clear from FIG. 6 and 7, most of the cooling element 307 is located in the device 51. However, there is a section of the cooling element 307 that exits the device 51. It is in this section of the cooling element 307 that exits the device 51 that the holes 317 for ventilation are located.

In FIG. 5-7 show in more detail an example of a device 51 configured to heat an aerosol generating material to vaporize at least one component of said aerosol generating material, typically to produce an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, rather than burning, the material to generate an aerosol.

The first end 53 is sometimes referred to herein as the mouthpiece or proximal end 53 of the device 51, and the second end 55 is sometimes referred to herein as the distal end 55 of the device 51. The device 51 includes an on/off button 57 so that the device 51 as a whole can be turned on and off as desired by the user.

The device 51 includes a housing 59 for housing and protecting various internal components of the device 51. In the example shown, the housing 59 includes a one-piece casing 11 which surrounds the perimeter of the device 51 and which is covered by a top panel 17 defining the generally "top" of the device 51 and which is covered by a bottom panel 19 defining the generally "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels, in addition to the top panel 17 and bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be releasably attached to the one-piece casing 11 to allow easy access to the inside of the device 51, or they can be “non-removable” attached to the one-piece casing 11, for example, to keep a user from gaining access to the inside of the device 51. In one example, the panels 17 and 19 are made of a plastic material containing, for example, glass-filled injection molded nylon, and the one-piece casing 11 is made of aluminum, although other materials and other manufacturing processes may be used.

The top panel 17 of device 51 includes an opening 20 at the mouth end 53 of device 51 through which, in use, an article 101, 301 containing aerosol generating material can be inserted by a user into device 51 and removed by a user from device 51.

In the housing 59, a heating device 23, a control circuit 25 and a power source 27 are disposed or attached thereto. In this example, the heating device 23, the control circuit 25, and the power source 27 are laterally adjacent to each other (i.e., adjacent to each other as viewed from the end), with the control circuit 25 located generally between the heating device 23 and the power source 27, although other arrangements are possible.

The control circuit 25 may include a controller, such as a microprocessor device, configured to control the heating of the aerosol generating material in the article 101, 301, which will be further described below.

The power source 27 may be, for example, a battery, which may be either a rechargeable (rechargeable) battery or a non-rechargeable battery. Examples of suitable batteries are, for example, a lithium ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery, and/or the like. The battery 27 is electrically connected to the heating device 23 to supply electrical power as needed and under the control of the control circuit 25 to heat the aerosol generating material in the article (as described, to vaporize the aerosol generating material without burning the material).

The advantage of positioning the power source 27 on the side, adjacent to the heating device 23, is that a physically large power source 25 can be used without the device 51 as a whole being unduly long. It is clear that, in general, a physically large power source 25 has a large capacity (i.e., the total electrical energy that can be supplied is often measured in Amp-hours or similar units) and thus the battery life for the device 51 can be longer.

In one example, the heating device 23 is generally in the form of a hollow cylindrical tube containing a hollow inner heating chamber 29 into which an article 101, 301 containing an aerosol generating material is inserted to be heated in use. Various designs of heating device 23 are possible. For example, heating device 23 may comprise a single heating element or may be configured as multiple heating elements aligned along the longitudinal axis of heating device 23. A single or each heating element may be annular or tubular, or at least partially annular or partially tubular in circumference. In one example, the single or each heating element may be a thin film heater. In another example, the single or each heating element may be made of a ceramic material. Examples of suitable ceramic materials are alumina and aluminum nitride and silicon nitride ceramics, which can be multi-layered and can be obtained by sintering. Other heating devices are possible, including, for example, induction heating elements, infrared heating elements that heat by emitting infrared radiation, or resistive heating elements made of, for example, resistive electrical winding.

In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. Heating device 23 is sized such that substantially the entire volume of aerosol material 103, 303 of article 101, 301 is inserted into heating device 23 when article 101, 301 is inserted into device 51.

The single or each heating element may be positioned such that selected zones of the aerosol generating material may be heated independently, for example, in turn (over time as described above) or together (simultaneously), as desired.

Heater 23 in this example is surrounded along at least part of its length by thermal insulator 31. Insulator 31 helps to reduce heat transfer from heater 23 to the outside of device 51. This helps to reduce the power requirements of heater 23 as this generally reduces heat loss. The insulator 31 also assists in the operation of the heating device 23 to keep the outside of the device 51 cool. In one example, the insulator 31 may be a double walled hose that provides a low pressure region between the two walls of the hose. That is, the insulator 31 may be, for example, a "vacuum" tube, that is, a tube that is at least partially evacuated to minimize heat transfer by conduction and/or convection. Other constructions of the insulator 31 are possible, including the use of heat insulating materials, including, for example, suitable foam material, in addition to or instead of the double wall sleeve.

The housing 59 may further comprise various internal support structures 37 designed to support all of the internal components as well as the heating device 23.

The device 51 further comprises an annular collar 33 which extends around the aperture 20 and protrudes from the aperture 20 into the housing 59, and generally a tubular chamber which is located between the annular collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f which, in this example, comprises a plurality of cooling fins 35f that are spaced apart along the outer surface of the chamber 35, and each of which is located circumferentially around the outer surface of the chamber 35. Between the hollow chamber 35 and the product 101, 301, when it is inserted into the device 51, there is an air gap 36 over at least part of the length of the hollow chamber 35. The air gap is located around the entire circumference of the product 101, 301 over at least part of the cooling segment 107.

The annular collar 33 comprises a plurality of ribs 60 that are arranged circumferentially around the boundary of the opening 20 and which protrude into the opening 20. The ribs 60 occupy space in the opening 20 such that the open space of the opening 20 at the locations of the ribs 60 is smaller than the open space of the opening 20 at locations without the ribs 60. The ribs 60 are configured to engage with the article 101, 301 that is inserted into the device to assist in securing it. and in device 51. Open spaces (not shown in the figure) defined by adjacent pairs of ribs 60 and product 101, 301 form ventilation paths around the exterior of product 101, 301. These ventilation paths allow hot vapors exiting product 101, 301 to exit device 51 and allow cooling air to flow into device 51 around product 101, 301 into air gap 36.

In operation, the product 101, 301 is retractably inserted into the insertion point 20 of the device 51 shown in FIG. 5-7. As shown in particular in FIG. 6, in one example, a volume of aerosol generating material 103, 301 that is located toward the distal end 115, 315 of article 101, 301 is entirely contained within the heating device 23 of device 51. The proximal end 113, 313 of article 101, 301 extends from device 51 and acts as a mouthpiece assembly for the user.

In operation, the heating device 23 will heat the article 101, 301 to vaporize at least one component of the aerosol generating material from the bulk of the aerosol generating material 103, 303.

The primary flow path for the heated vaporized components from the bulk of the aerosol generating material 103, 303 is axially through the article 101, 301, through the chamber located within the cooling segment 107, 307, through the filtration segment 109, 309, through the mouthpiece segment 111, 313 to the user. In one example, the temperature of the heated vaporized components that are produced from the volume of aerosol generating material is between 60° C. and 250° C., which may be above an acceptable temperature for inhalation by the user. As the heated vaporized component moves through the cooling segment 107, 307, it will cool and some of the vaporized components will condense on the inner surface of the cooling segment 107, 307.

In the product examples 301 shown in FIG. 3 and 4, cooling air will be able to enter the cooling segment 307 through the ventilation holes 317 that are provided in the cooling segment 307. This cooling air will mix with the heated evaporative components to provide additional cooling to the heated evaporative components.

In some cases, the preparation of the material for generating an aerosol may include the following: (a) obtaining a slurry that contains the components of an amorphous solid material, (b) forming a slurry layer, (c) curing the slurry to form a gel, and (d) drying the gel to form an amorphous solid material.

Step (b) forming the slurry layer may include spraying, casting or extruding the slurry, for example. In some cases, the slurry layer is formed by electrospraying the slurry. In some cases, the slurry layer is formed by casting the slurry.

In some cases, steps (b) and/or (c) and/or (d) may at least partially be performed simultaneously (eg during electrospray). In some cases, these steps may be performed sequentially.

Step (b) may include forming a slurry layer on the carrier material.

In some examples, the slurry has a viscosity of about 10 to about 20 Pa.s at 46.5°C, such as about 14 to about 16 Pa.s at 46.5°C.

Step (c) curing the gel may include adding a curing agent to the slurry. For example, the slurry may contain sodium, potassium, or ammonium alginate as a gelling agent, and a hardening agent containing a calcium source (eg, calcium chloride) may be added to the slurry to form a calcium alginate gel.

The total amount of curing agent, such a source of calcium, may be 0.5 to 5 wt.% (values calculated based on dry weight). The inventors have found that adding too little curing agent can result in an amorphous solid material in which the components of the amorphous solid material are not stabilized, and this causes these components to fall out of the amorphous solid material. The inventors have found that adding too much curing agent results in an amorphous solid material that is very sticky and therefore less comfortable to handle.

However, in some cases no curing agent is needed; the tobacco extract may contain enough calcium to effect gelation.

Alginic acid salts are derivatives of alginic acid and are usually high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic acid (G) units linked together by (1,4)-glycosidic bonds to form a polysaccharide. When calcium cations are added, the alginate crosslinks to form a gel. The inventors have determined that salts of alginic acid with a high content of monomer G more easily form a gel when a source of calcium is added. Therefore, in some cases, the gel precursor may contain an alginic acid salt in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

The suspension itself may also form part of the invention. In some cases, the slurry solvent may be essentially water, or may be water. In some cases, the suspension may contain a solvent in an amount of about 50 wt.%, 60 wt.%, 70 wt.%, 80 wt.% or 90 wt.% (WWB).

In cases where the solvent consists of water, the dry weight of the contents of the suspension may correspond to the dry weight of the contents of the amorphous solid material. Thus, the discussion here of solid material composition is explicitly described in conjunction with the slurry aspect of the invention.

Examples of embodiments of the invention

In some embodiments, the amorphous solid material contains menthol.

Particular embodiments of the invention containing the menthol amorphous solid material may be particularly suitable for incorporation into an article/device assembly for generating a pulverized sheet aerosol. In these embodiments, the amorphous solid material may have the following composition (DWB): gelling agent (preferably containing alginate, more preferably containing a combination of alginate and pectin) in an amount of from about 20 wt.% to about 40 wt.% or from about 25 wt.% to 35 wt.%; menthol in an amount of from about 35 wt.% to about 60 wt.% or from about 40 wt.% to 55 wt.%; an aerosol generating agent (preferably containing glycerol) in an amount of from about 10 wt.% to about 30 wt.%, or from about 15 wt.% to about 25 wt.% (DWB).

In one embodiment of the invention, the amorphous solid material contains about 32-33% by weight of a mixture of gelling agents that are alginate/pectin; about 47 - 48 wt.% menthol flavor; and about 19-20% by weight of the aerosol generating agent being glycerol (DWB).

As noted above, the amorphous solid material according to these embodiments of the invention may be included in an article/device assembly for generating an aerosol in the form of a pulverized sheet. The shredded sheet may be provided in the product/device assembly in admixture with cut tobacco. Alternatively, the amorphous solid material may be provided as an uncomminuted sheet. Suitably, the shredded or unshredded sheet has a thickness of from about 0.015 mm to about 1 mm, preferably from about 0.02 mm to about 0.07 mm.

Particular embodiments of the menthol-containing amorphous solid material may be particularly suitable for inclusion in an aerosol generating article/device assembly in the form of a sheet, such as a sheet surrounding a rod of aerosolizable material (eg, tobacco). In these embodiments, the amorphous solid material may have the following composition (DWB): gelling agent (preferably containing alginate, more preferably containing a combination of alginate and pectin) in an amount of from about 5 wt.% to about 40 wt.% or from about 10 wt.% to 30 wt.%; menthol in an amount of from about 10 wt.% to about 50 wt.% or from about 15 wt.% to 40 wt.%; an aerosol generating agent (preferably containing glycerol) in an amount of from about 5 wt.% to about 40 wt.%, or from about 10 wt.% to about 35 wt.%; and, if necessary, a filler in an amount up to 60 wt.% - for example, in an amount of from 5 wt.% to 20 wt.% or from about 40 wt.% to 60 wt.% (DWB).

In one of these embodiments of the invention, the amorphous solid material contains about 11 wt.% mixture of gelling substances, which are alginate/pectin; about 56 wt.% wood pulp filler, about 18 wt.% menthol flavor and about 15 wt.% glycerol (DWB).

In another embodiment of these embodiments of the invention, the amorphous solid material contains about 22 wt.% mixture of gelling substances, which are alginate/pectin; about 12 wt.% wood pulp filler, about 36 wt.% menthol flavor and about 30 wt.% glycerol (DWB).

As noted above, the amorphous solid material of these embodiments may be present in sheet form. In one embodiment of the invention, this sheet is provided on a carrier material that contains paper. In one embodiment of the invention, this sheet is provided on a carrier material which comprises a metal foil, expediently aluminum metal foil. In this embodiment, the amorphous solid material may be adjacent to the metal foil.

In one embodiment of the invention, the sheet forms part of a laminate with a layer (preferably which contains paper) that is attached to the top and bottom surfaces of the sheet. Suitably, the sheet of amorphous solid material has a thickness of from about 0.015 mm to about 1 mm.

In some embodiments, the amorphous solid material contains a flavor that does not contain menthol. In these embodiments, the amorphous solid material may have the following composition (DWB): gelling agent (preferably containing alginate) in an amount of from about 5 wt.% to about 40 wt.%, or from about 10 wt.% to about 35 wt.%, or from about 20 wt.% to about 35 wt.%; flavoring in an amount of from about 0.1 wt.% to about 40 wt.% or from about 1 wt.% to about 30 wt.%, or from about 1 wt.% to about 20 wt.%, or from about 5 wt.% to about 20 wt.%; an aerosol generating agent (preferably containing glycerin) in an amount of from 15 wt.% to 75 wt.%, or from about 30 wt.% to about 70 wt.%, or from about 50 wt.% to about 65 wt.%; and, if necessary, a filler (preferably wood pulp) in an amount of less than about 60 wt.% or about 20 wt.% or about 10 wt.% or about 5 wt.% (preferably, the amorphous solid material does not contain filler) (DWB).

In one of these embodiments, the amorphous solid material contains about 27 wt. % alginate gelling agent, about 14 wt. % flavor, and about 57 wt.

In another embodiment of these embodiments, the amorphous solid material contains about 29 wt. % alginate gelling agent, about 9 wt. % flavor, and about 60 wt. % glycerol (DWB).

The amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly in the form of a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly in the form of a sheet, such as a sheet surrounding a rod of aerosolizable material (eg, tobacco). Alternatively, the amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly as a layer portion located on the carrier material.

In some embodiments, the amorphous solid material contains tobacco extract. In these embodiments, the amorphous solid material may have the following composition (DWB): gelling agent (preferably containing alginate) in an amount of from about 5 wt.% to about 40 wt.%, or from about 10 wt.% to 30 wt.%, or from about 15 wt.% to 25 wt.%; tobacco extract in an amount of from about 30 wt.% to about 60 wt.% or from about 40 wt.% to 55 wt.% or from about 45 wt.% to about 50 wt.%; an aerosol generating agent (preferably containing glycerol) in an amount of from about 10 wt.% to about 50 wt.%, or from about 20 wt.% to about 40 wt.%, or from about 25 wt.% to about 35 wt.% (DWB).

In one embodiment, the amorphous solid material contains about 20% by weight of an alginate gelling agent, about 48% by weight of Virginia tobacco extract, and about 32% by weight of glycerol (DWB).

The amorphous solid material according to these embodiments of the invention may have any suitable water content. For example, the amorphous solid material may have a water content of from about 5 wt.% to about 15 wt.%, or from about 7 wt.% to about 13 wt.%, or about 10 wt.%.

The amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly in the form of a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly in the form of a sheet, such as a sheet surrounding a rod of aerosolizable material (eg, tobacco). Alternatively, the amorphous solid material of these embodiments may be included in the aerosol generating article/device assembly as a layer portion located on the carrier material. Suitably, in any of these embodiments, the thickness of the amorphous solid material is from about 50 µm to about 200 µm, or from about 50 µm to about 100 µm, or from about 60 µm to about 90 µm, suitably the thickness is about 77 µm.

The slurry for producing this amorphous solid material may also form part of the invention. In some cases, the suspension may have an elastic modulus of from about 5 to 1200 Pa (also called storage modulus); in some cases, the slurry may have a viscosity modulus of about 5 to 600 Pa (also referred to as loss modulus).

Definitions

The active substance herein may be a physiologically active material, which is a material intended to achieve or improve a physiological response. The active substance, for example, can be selected from nutraceuticals, nootropics, psychoactive substances. The active substance may be of natural origin or may be obtained synthetically. The active substance may contain, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids or their constituents, derivatives or combinations thereof. The active substance may contain one or more constituents, derivatives or extracts of tobacco, cannabis or other herbal component.

In some embodiments of the invention, the active substance contains nicotine.

In some embodiments of the invention, the active substance contains caffeine, melatonin or vitamin B12.

As noted herein, the active substance may contain one or more constituents, derivatives or extracts of cannabis, for example, one or more cannabinoids or terpenes.

Cannabinoids are a class of natural or synthetic chemical compounds that act on cannabinoid receptors (i.e., CB1 and CB2) on cells that inhibit the release of neurotransmitters in the brain. Cannabinoids can be obtained naturally (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or can be artificially produced (synthetic cannabinoids). Cannabis species are at least 85 different phytocannabinoids and are divided into subclasses containing cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols and other cannabinoids. The cannabinoids found in cannabis include but are not limited to: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannadivarin (CBDV), cannabichromevarin ( CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

Here we note that the active substance may contain or may be obtained from one or more plant components or constituents, their derivatives or their extracts. As used herein, the term "botanical component" includes any material derived from plants, including, but not limited to: extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, peels, and the like. Alternatively, the material may contain an active compound naturally present in the plant component and obtained synthetically. This material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, grains, pieces, strips, sheets, or the like. Examples of herbal ingredients are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, bay, licorice (licorice), matcha, mate, orange peel, papaya, rose, sage, tea, such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed (anise), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, perilla perennial, turmeric, turmeric, sandalwood cilantro, bergamot, orange blossom, myrtle, cassia, valerian, capsicum, nutmeg, demien, marjoram, olive, lemon balm, lemon basil, chives, cumin, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorine ophyll, baobab, or any combination thereof. Mint can be selected from the following types of mint: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the botanical component is selected from eucalyptus, star anise, cocoa, and hemp.

In some embodiments, the botanical component is selected from rooibos and fennel.

As used herein, the terms "flavor" and "flavor" refer to materials that, where permitted by local law, may be used to create a desired taste, aroma, or other somatosensory experience in an adult product. They may include natural flavors, botanicals, botanical extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white bark, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices). ai, asian spices, herb, wintergreen, cherry, berry, elderberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, pitahaya, cucumber, blueberry, mulberry, citrus, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint , Peppermint, Lavender, Aloe Vera, Cardamom, Celery, Cascarilla, Nutmeg, Sandalwood, Bergamot, Geranium, Khat, Nasvay, Betel, Shisha, Pine, Honey Essence, Rose Oil, Vanilla, Lemon Oil, Orange Oil, Orange Blossom, Cherry, Cassia, Cumin, Cognac, Jasmine, Ylang Ylang, sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, bay, mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderberry, basi lychee, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon zest, mint, perilla perennial, turmeric, cilantro, myrtle, cassia, valerian, cloves, nutmeg, demien, marjoram, olive, lemon balm, lemon basil, chives, cumin, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor blockers, sensory receptor activators or stimulants, sugars, and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They can be imitations, synthetic or natural ingredients, or mixtures. They may be in any suitable form, such as being a liquid such as an oil, a solid such as a powder, or a gas.

Desirably, the fragrance may contain one or more mint fragrances, suitably, the fragrance of any mint oil from the genus Mentha. Desirably, the flavor may contain, essentially, consist or consist of menthol.

In some embodiments, the fragrance contains menthol, spearmint and/or peppermint.

In some embodiments, the fragrance contains cucumber, blueberry, citrus, and/or ginseng aroma components.

In some embodiments, the fragrance contains eugenol.

In some embodiments of the invention, the flavor contains flavor components isolated from tobacco.

In some embodiments of the invention, the aroma contains aroma components isolated from cannabis.

In some embodiments of the invention, the aroma may contain a sensible substance that is intended to achieve a somatosensory sensation, which is usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the olfactory or gustatory nerves, and these may include substances that provide the effect of heating, cooling, tingling, numbness. A suitable heat agent may be, inter alia, vanillyl ethyl ether, and a suitable coolant may be, inter alia, eucalyptol, WS-3.

In this document, the term "aerosol generating agent" is a substance that promotes the production of an aerosol. The aerosol generating agent may assist in aerosol generation by facilitating initial evaporation and/or condensation of the gas into an inhalable particulate and/or liquid aerosol.

Suitable aerosol formulations include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol, or glycols such as propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling hydrocarbons, acids such as lactic acid, glycerol compound derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. Advantageously, the aerosol generating agent may have a composition that does not dissolve menthol. Suitably, the aerosol generating agent may comprise essentially, or consist of, glycerol.

As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives. The term "tobacco material" may include one or more of the following: tobacco, tobacco derivatives, exploded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may contain one or more of the following: ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and/or tobacco extract.

The tobacco used to make the tobacco material may be any suitable tobacco, such as single grade tobacco or tobacco blends, cut or whole leaf tobacco, including Virginia and/or Burley tobacco and/or Oriental tobacco. It can also be "fine" tobacco particles or tobacco dust, or exploded tobacco, stems, exploded stems, or other processed stem materials such as cut and rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may contain tobacco fibers and may be made by casting, a papermaking approach using a long wire paper machine with the addition of tobacco extract, or by extrusion.

All percentages by weight described herein (denoted as wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All mass ratios are also calculated on a dry weight basis. Weight given on a dry basis refers to the entire extract or suspension, or material other than water, and may contain components that are themselves liquid at room temperature and pressure, such as glycerin.

Conversely, the percentage by weight given on a wet weight basis applies to all components, including water.

For the avoidance of ambiguity, when the term “comprises” is used in the present description when defining an invention or feature of an invention, embodiments of the invention are also described in which instead of “comprises”, the invention or feature can be defined using the terms “essentially consists of” or “consists of”. Reference to material "having" certain features means that those features are included in, contained in, or retained in the material.

The embodiments of the invention described above are to be understood as illustrative examples of the invention. It should be understood that any feature described in connection with any embodiment of the invention may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other embodiment of the invention or with any other embodiment of the invention. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the invention as defined by the appended claims.

Claims (18)

1. An aerosol generating substrate that contains an aerosol generating material, wherein said aerosol generating material comprises an amorphous solid material, wherein said amorphous solid material contains an aerosol generating material, wherein when the aerosol generating material is heated to 370° C. for a period of ten seconds, with an air flow of 1.95 l/min, at least 65 wt.% of the material for producing aerosol aerosol work is converted to aerosol; wherein said aerosol generating substrate comprises a carrier material on which an amorphous solid material is provided. 2. The aerosol generating substrate according to claim 1, wherein when the aerosol generating material is heated to 370°C for a period of ten seconds, with an air flow of 1.95 l/min, at least 70 wt.% of the aerosol generating substance is converted into an aerosol. 3. The aerosol generating substrate according to claim 1 or 2, wherein the amorphous solid material contains the aerosol generating agent in an amount of 5-80% by weight, the values being calculated based on dry weight. 4. Substrate for generating aerosol according to any one of paragraphs. 1-3, wherein the aerosol generating agent is selected from the following: erythritol, sorbitol, glycerin, glycols, monohydric alcohols, high boiling point hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. 5. The aerosol generating substrate of claim 4, wherein the aerosol generating agent comprises glycerin. 6. Substrate for generating aerosol according to any one of paragraphs. 1-5, in which the amorphous solid material contains: - gelling agent in the amount of 1-60 wt.%; and/or - substance for the production of aerosol in the amount of 5-80 wt.%; and/or - active substance in the amount of 10-60 wt.%; - and, if necessary, flavoring; these masses being calculated on a dry mass basis. 7. The aerosol generation support of claim 6, wherein the amorphous solid material is a hydrogel and contains less than about 20% by weight water, the values calculated based on wet weight. 8. Substrate for generating aerosol according to any one of paragraphs. 6, 7, in which the gelling agent contains one or more compounds selected from the group containing alginates, pectins, starches and starch derivatives, celluloses and cellulose derivatives, gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. 9. Substrate for generating aerosol according to any one of paragraphs. 1-8, which contains a flavoring agent in an amount of about 0.1-80 wt.%, and the values are calculated on the basis of dry weight. 10. Substrate for generating aerosol according to any one of paragraphs. 6-9, in which the active substance is a tobacco extract, and said tobacco extract is an aqueous extract obtained by extraction with water. 11. Substrate for the production of aerosol according to any one of paragraphs. 1-10, wherein the carrier material comprises metal foil, paper, carbon paper, parchment paper, ceramics, allotropes of carbon, cardboard, tobacco material, wood, or combinations thereof. 12. Product for the production of aerosol, containing the substrate for the production according to any one of paragraphs. 1-11. 13. Device assembly for the production of aerosol, which contains a substrate for the production of aerosol according to any one of paragraphs. 1-11 or the article of claim 12 and a heater that is configured to heat, but not burn, the aerosol generating substrate.